1 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No ACMA Awards Company Name : Plant Location : Category : LARGE Excellence in Export

2 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Index ( For office use only except page no. ) S.N.SectionPage No. Max. MarksActual Marks 1 Work Environment & Employee Involvement Customer Assessment150 3 Export Operation Performance Export Market Performance Quality Performance.150 Total 1000 ACMA Centre for Technology (ACT) Godrej Eternia-C, ‘B’ Wing, '10th Floor, Office No.- C, Old Mumbai Pune Highway Wakdewadi, Shivaji Nagar, Pune – , India. For Administrative Queries: Mr. Jitender Rana – Mobile – Ms. Sakshi Karkamkar – Mobile – Mr. Binny Tomy - Mobile For Technical Queries: Mr. V K Sharma Mobile : Mr. Sunil Mutha - Mobile Ms. Sapana Baravkar Mobile :

3 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Letter for Submission of Award application Company letterhead details ( Logo, Address ) To, The Secretariat ( ACMA Awards ), ACMA Centre for Technology Godrej Eternia, ”B” Wing, 10th Floor, Office No. C, Old Mumbai –Pune Highway, Wakdewadi, Shivaji Nagar Pune – , India Tel No ( Ms. Sakshi ) We are pleased to submit the application for ACMA Award for Excellence in Export in Large category. All data submitted is duly verified and true to the best of our knowledge. With regards ( Name & Designation of the Plant CEO ) Company History with ACMA Awards (last 3 years) Sr. No.Financial Year (April to March) ACMA Awards Category- Applied Award / Certificate Won Note- If you have applied & won multiple awards in one year, please mention accordingly.

4 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 To, Applicant Company CONFIDENTIALITY STATEMENT As a part of the ACMA Awards Process, applicant companies provide business, market, technical, financial information/documents and top customers details in the application. Such information could also be related to intellectual property i.e, patents, product development etc. ACMA take reasonable care to keep the above information confidential and shall not divulge it to third party and/or not use it for their own purpose, any part of this information in the course of assessment and thereafter. I agree. On behalf of ACMA Sd/- Director General Automotive Component Manufacturers Association of India 6th Floor, The Capital Court Olof Palme Marg, Munirka New Delhi , India

5 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Company’s Details 1.Name of the corporate group (if company is part of a corporate group): - ( Underline the plant for which application is sent ) Plant Address : 2. Name of the Chief executive of the corporate group- 3Chief Executive (Site) details : Name : Designation : Mobile : Land line with extension : Fax No. 4. Plant Head ( Next to Chief Executive (Site)) details : Name : Designation : Mobile : Land line with extension : Fax No. ( If Sr. No. 3 & 4 are same, then provide next level person details at Sr. No. 4 )

6 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Company’s Details 5.* Company Group Annual Sales Turnover (in INR Cr.) for Year : 6.Plant (for which application is submitted) turnover ( in INR Cr.) for Year : 7.Year of Establishment : Company _______, Plant ___________ 8.Total Employees : Company ___________, Plant _____________ 9. Do you have a Joint Venture : ( If Yes, Mention the partner name ) 10. Company’s Key products : 11. Plant’s Key products : 12.Plant’s key manufacturing processes : 13.Plant’s Key competitors : 14. Plant’s Major Certifications : * Award Criteria for Excellence in Export (Large Category)- Company Group Annual Sales Turnover for Year > INR 100 Cr

7 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 As a part of ACMA Award process, feedback from your major customers will be obtained directly and will be provided to Jury. The same will be provided to you as a part of feedback report. Top 2 Business Customer’s Key person details are required (Without customer details, application will not be processed). Customer Details Mandatory requirement S. NoCustomerLocation% Business share (from the plant ) Customer Key person name & Designation Mobile Number & E mail 1 Manufacturing Head Incoming Quality Head 2 Manufacturing Head Incoming Quality Head Note- In addition to application & site diagnosis, Customer feedback scores will be also considered for final scores.

8 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Use this slide to brief about your company / Plant. It includes Product names / photos, Plant facility photographs. Company / Plant Information

9 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Route Map to reach your plant Contact person name & designation: Name : Designation : Mobile : Landline : ( STD Code ) ( Number ) : Ext. ( if any ) Provide here route map to your company for site diagnosis ( Site diagnosis is carried out if your application is shortlisted )

10 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 S. N. AreaTotal Marks Actual Marks ( for Office Use only ) % 1 Work Environment & Employee Involvement Customer Assessment150 3 Export Operation Performance Export Market Performance Quality Performance.150 Total1000 ( For office use only ) Company performance at a glance ( Following radar chart shows the scores for each main area as per questionnaire, scores are converted to % ) RADAR Chart

11 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Section 1 Work Environment & Employee Involvement. Total Marks = 150 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 1.AWork Place Management40 1.B Suggestions / Kaizens Per Employee 20 1.CAbsenteeism10 1.DTraining10 1.ESmall Group Activities10 1.FSafety30 1.G Environment Management 30 TOTAL150 ( For office use only )

12 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (i) Specify status in below mentioned checklist for “Must be facilities” for all company employees ? Illustrate with photographs of some examples (15) Must be facilities for all company employees Sr. No. DescriptionStatus 1 Jogging track inside shop floor, along walls OK / Not OK 2 Trees in plant campus OK / Not OK 3 No earth should be visible in entire company area. There should be concrete, tar roads or green lawns. OK / Not OK 4 No truck / fork-lift inside shop floor OK / Not OK 5 Clean toilet blocks inside shop floor, dry & smell free OK / Not OK 6 No nails to be used anywhere in the factory premises. OK / Not OK 7 All employees to wear uniform, shoes and necessary safety gadgets. OK / Not OK 8 Noise free DG sets & compressor OK / Not OK 9 Clean wash room / change room and rest room facilities OK / Not OK 10 Hygienic kitchen, drinking water & dinning hall. OK / Not OK 11 Good recreational facilities OK / Not OK 12 Appropriate fire fighting equipments should be placed at accessible locations OK / Not OK 13 Central display board ( 80 % Digital ) OK / Not OK Photo 1.Work Environment and employee engagement (1.A) Work Place Management Total= 40

13 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 1.Work Environment and employee engagement (ii) illustrate how concept of 5S/house keeping has been deployed in your plant? (5) (1.A) Work Place Management Total= 40 (iv) What methods are adopted to assess 5S levels/scores? (show last one year trend in line graph, illustrate it with your internal Target line.). (5) Formula 5 S Score = Lowest zone or area score of that month in % (v) How you drive 5S in your Organization (making Zones, accountability, checklist, inclusion of all areas, trophy, audits, corrective actions, non conformity points closure, cross audits, negative marking for critical points, time allotted for m/c cleaning) (10) (iii) How employees are motivated to follow 5s ? (5)

14 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (1.B) Suggestions / Kaizens Per Employee Total= 20 (i) Is there a suggestion scheme in the company and How company encourages employees to give suggestions? ? Pls Describe: (5) (ii) How company ensures the suggestions are implemented? Pls describe: (5) 1.Work Environment and employee engagement

15 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 1.Work Environment and employee engagement (1.B) Suggestions / Kaizens Per Employee Total= 20 (iv) Is there a forum (as well as escalation process) for employees to raise issues / concerns etc.--- shop floor / HR / personal etc. If yes, please elaborate.. (5) (iii) Trends of number of suggestions implemented / employee / month? (show last one year trend in line graph, illustrate it with your internal Target line.). (5) Formula Total suggestions + Kaizen Implemented in that month Suggestions / Employee = X 100 Total direct employees ( Operatives ) for the month

16 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (1.C) Absenteeism Total= 10 (i) What is absenteeism data ( Average) for the year ? What are the trends in regards to total absenteeism? (Three year trend in bar graph, illustrate it with your internal Target line.) ( 5 ) Authorized = % Unauthorized = % Total = % (ii) What efforts organization takes to reduce absenteeism? ( 5 ) 1.Work Environment and employee engagement Formula Total absent man-hours for the month ( Authorized + Unauthorized ) Absenteeism = X 100 Total man hours for the month

17 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (1.D) TRAINING Total= 10 (i) In which areas do you provide training to your employees ? List some benefits achieved by trainings in recent past. What is the trend of the training hours / employee over the years? (show last three year trend in bar graph, illustrate it with your internal Target line.) ( 5 ) Training Areas : 1.Work Environment and employee engagement (ii) How training effectiveness is measured and Benefits of Training : Tangible ( in Rs. Lacs ) & Intangible : (Give details for TWO shining examples) : ( 5 ) Formula Total training man-hours for all employees for year Training hours/employee / year = Total employees

18 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (1.E) Small Group Activities Total= 10 (i)Explain how company encourages small group activities. Do small group participate in the Quality Conventions-Group / State level / National. Show certificates / trophy photographs. (5) (iii) How many active groups are present in the current year? % employee involvement In QC Activity? (show last three year trend in bar graph). (5) 1.Work Environment and employee engagement No. of Active groups

19 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (1.F) SAFETY Total= 30 Pls describe: with text / Photos (i)How company ensures Safe work practices? (5) (ii) Proactive measures taken by company to reduce accidents (5) (iii) Number of accident free days ( Cumulative ) (5) : 1.Work Environment and employee engagement

20 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 1.Work Environment and employee engagement (1.F) SAFETY Total= 30 Formula No. of accidents Frequency rate = X 10 6 Total man hours Formula Total man-days lost Severity rate = X 10 6 Total man hours (iv) What are the current accident levels? (Show last one year data in line graph) (15) A) Frequency (nos.) Minor + Major both B) Severity (man hrs. lost)

21 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (1.G) Environment Management Total= 30 (i) What is the frequency of scarp disposal? (Pl explain is it Daily / Weekly … ) (5) (ii) Does company has resources conservation strategy? List some recent achievements of company to conserve resource -electricity, water, material, etc ? (10) 1.Work Environment and employee engagement

22 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (iii) Please describe the practices of the company to reduce pollution? (10) (1.G) ENVIRONMENT MANAGEMENT Total= 30 1.Work Environment and employee engagement (iv) Mention two achievements of major improvements done to save environment. (5)

23 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Section 2 Customer Assessment Total Marks = 150 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 2.A SOB with 3 Major Customers 30 2.BCustomer Feedback40 2.CFeedback Analysis60 2.DCustomer Awards20 TOTAL150 ( For office use only )

24 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (i) % SOB with Major 3 Export Customers (show last 3 yr trend), illustrate it with your internal Target line. (20) (2.A ) Share Of Business with 3 Major Export Customers Total= 30 (ii) Why business has reduced or Improved ? Explain with case to case (10) 2. Customer Assessment

25 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (ii) How do you listen to customer ? How customer issues are communicated and actions are taken ? (20) (2.B ) Customer Feedback Total= 40 (i) Does the company has an organization structure to address customer needs in a proactive way and also respond quickly to queries / issues etc? (10) (iii) Is there a warranty involved in supplies? If yes, is there a system to address the same? (10 ) 2. Customer Assessment Photo

26 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (i) How do you analyze this feedback and take actions in weak areas? Explain with a case study. (30) (2.C ) Feedback Analysis Total= Customer Assessment (ii) Is there a data monitoring system in place to review field performance in export markets? (15) (iii) Is there a system to address the need of service parts requirements in export market? (15)

27 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (2.D ) Customer Awards Total= 20 (ii) Awards / Recognition by Key Customers from Domestic and Export Customers (trend of last 3 years) (15) Note : If your Customer does not has a system of Awards, Mention what kind of supplier recognition is followed by Customer. 2. Customer Assessment (i) How you capture unspoken customer voice? ( 5 )

28 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Section 3 Export Operation Performance Total Marks = 300 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 3.ASales Growth80 3.BExport OEM / Tier 1 Sales50 3.CProduct recall readiness50 3.D New Product added in Export 50 3.ERoyalty Payments20 3.FGeneral50 TOTAL300 ( For office use only )

29 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (3.A ) Sales Growth Total= 80 (ii) How Total sales improved ? If not improved, what are the reasons ? (20) (I) Total sales in Rs. Crore and % of total Sales Growth ( Last 3 years Trend, illustrate it with your internal Target line.) (20)

30 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (3.A ) Sales Growth Total= 80 (iv) How export sales improved ? If not improved, what are the reasons ? (20) (iii) Total Export Sales, In Rs. Crore and % growth in Export Sales ( Last 3 years Trend, illustrate it with your internal Target line.) – (20)

31 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (i) OEM/Tier 1 Export Sales and % of Total Exports (In Rs Crore ) ( last 3 years Trend, illustrate it with your internal Target line.) – (15) (3.B ) OEM / Tier 1 Export Sales Total= 50 (ii) How has OEM / Tier 1 sales improved ? If not improved, what are the reasons ? (15)

32 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (3.B ) OEM / Tier 1 Export Sales Total= 50 (iv) How has Aftermarket sales improved ? If not improved, what are the reasons ? (10) (iii) Total aftermarket Export Sales, In Rs. Crore and % growth in After Market Export Sales ( Last 3 years Trend, illustrate it with your internal Target line.) – (10)

33 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (i)How company prepared for product recall related issues, mention in brief actions taken in plant? (30) (3.C) Product recall readiness Total= 50 (ii) ) Mention two shining examples of action taken which has reduced your liability (20)

34 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (3.D) New Product added for Export Total= 50 (i) Number of new products added from existing product portfolio for export market and % of sales contribution from these new products to Exports in last three years –show 3 years trend graph., illustrate it with your internal Target line.(10) (ii) Number of entirely new products added and % of sales contribution from these new products to Exports in last three years –show 3 years trend graph, illustrate it with your internal Target line. (10)

35 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (iii) Show process / roadmap for development of new products for export and its achievement status (10) (3.D) New Product added for Export Total= 50 (iv) Is there a method to communicate design changes to export markets customers to address supply conditions as well as stocked material at warehouses / service outlets etc? (10) (v) How is the engineering change implementation effected for OE export customers? What is the system for aftermarket supplies? (10)

36 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (3.E) Royalty Payments Total= 20 (i) Royalty payments over last 3 years (in Rs. Crore ), illustrate it with your internal Target line.(10) (ii) How have royalty payments reduced ? (10)

37 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (3.F) GeneralTotal= 50 (i) Is there a risk management system in place to address export market litigations / law suits etc particulars with reference to safety part supplies? (10) (ii) Is the document retention period for exports clearly defined? (10) (iii) Does the above address the statutory requirements of the country of export as well as customer requirements? (10)

38 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Operation Performance (3.F) GeneralTotal= 50 (iv) Are process changes / engineering changes also validated and documented? (10) (v) How is the quality of safety critical parts ensured on periodic basis? (10)

39 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Section 4 Export Market Performance Total Marks = 250 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 4.A Export growth in Established Market B Breakthrough Achievements for Capturing Markets 100 TOTAL250 ( For office use only )

40 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Market Performance (i) Export destinations (Names) – (20) (ii) Principal OEMs / Tier 1 customers – (20) (4.A) Export Growth in Established Market Total= 150

41 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Market Performance (4.A) Export Growth in Established Market Total= 150 (iii) Export Growth in established Market (Rs. Crore ) Last 3 years Trend for Developed Countries ?, illustrate it with your internal Target line. (40) ( You can edit / add your export countries in this graph ) (iv) What are the initiatives to improve growth in developed countries? ( 20 )

42 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Market Performance (4.A) Export Growth in Established Market Total= 150 (v) Export Growth in developing Market (Rs. Crore ). Last 3 years Trend for Developing countries, illustrate it with your internal Target line. ( You can edit / add your export countries in this graph ) (30) (iv) What are the initiatives to improve growth in developing countries ? ( 20 )

43 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Market Performance (4.B) Breakthrough Achievements for capturing new Markets Total= 100 (i) Cost competitiveness for capturing new markets (40) (ii) Use of Technology for capturing new markets (20)

44 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Export Market Performance (iii) Quality and Delivery performance for capturing new markets (20) (iv) Through Innovation (20) (4.B) Breakthrough Achievements for capturing new Markets Total= 100

45 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Section 5 Quality Performance Total Marks = 150 S.N.Sub topic Total Marks Actual Marks ( for office use ) % 5.AIn-House Rejection30 5.BCost of Poor Quality25 5.CRework25 5.DPoka-Yokes25 5.ECustomer Complaints25 5.FCustomer Returns20 TOTAL150 ( For office use only )

46 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (5.A) In-House Rejection Total= Quality Performance (i) What are the trends of the Total in-house rejection in PPM ? (show last 3 year data in bar graph, illustrate it with your internal Target line.) (10) (ii) Please describe the actions taken to reduce the in- house rejection (10)

47 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (5.A) In-House Rejection Total= Quality Performance S.N.DefectBefore PPMAfter PPMActions Taken (iii) Provide example of actions by which you are able to achieve zero defect for In-House rejection (10)

48 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No Quality Performance (5.B) Cost of poor Quality ( COPQ) Total = 25 (i)Show cost of poor quality trends for last three years (10) (ii) Mention elements of Cost of poor quality and its trend for last 2 years. (10) S.N.COPQ Element Before % After % Remarks Insert more rows, total 15 required (iii) Provide example of actions by which you are able to reduce COPQ ( 5 )

49 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (5.C) Rework Total= Quality Performance (ii) Explain efforts taken to reduce rework. (10) (i) What is the current level of the rework in PPM ? (show trend for last 3 year in bar graph, illustrate it with your internal Target line.) (5)

50 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (5.C) Rework Total= Quality Performance (iii) Please give details of action taken to reduce rework? (10) S.N.ReworkBefore PPMAfter PPMActions Taken

51 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (5.D) Poka-yoke Total= Quality Performance (i) How company identifies need for Poka-Yoke ? ( 5 ) (ii) What % of CTQs are controlled by Poka Yoke? (5) % = (iv) How do you ensure effectiveness of Poka yoke? (5 ) (iii) What % of Customer complaints are closed by Poka Yoke in ? (5) % =

52 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (5.D) Poka-yokes Total= Quality Performance (v) Show innovative examples of poka-yoke & Effect on overall Rejection of that Product ( 5) S.N.ProductBefore Poka-Yoke Rejection PPM After Poka- yoke Rejection PPM Poka-yokes done Before – After Photo Before After

53 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (5.E) Customer Complaints Total= Quality Performance S.N.Export Complaints Root CauseAction Taken (i) Customer complaints for Domestic and export customers (show last 3 yr trend, illustrate it with your internal Target line.) (15) (ii) What actions are initiated to eliminate export Complaints ? (10 )

54 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 (5.F) Customer Returns Total= Quality Performance S.N.Export ReturnsRoot CauseAction Taken (i) Customer Returns PPM for Domestic and export customers (show last 3 yr trend, illustrate it with your internal Target line.) (10) (ii) What actions are initiated to eliminate export Customer Returns? (10 )

55 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 Summary of Achievements for the year ( Company has to fill up )

56 ACMA Awards : Excellence in Export (Large) PM_44_F2, Rev No.02 For Company: Show your companies excellent photos